Robotic Wire Termination System

ABSTRACT

A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.17/512,981 filed on Oct. 28, 2021 (Docket No. ONAN-058), which is acontinuation of U.S. application Ser. No. 16/364,017 filed on Mar. 25,2019 now issued as U.S. Pat. No. 11,161,205 (Docket No. ONAN-026), whichis a continuation of U.S. application Ser. No. 14/693,292 filed on Apr.22, 2015 now issued as U.S. Pat. No. 10,239,164 (Docket No. ONAN-007),which is a continuation-in-part of U.S. application Ser. No. 14/060,852filed on Oct. 23, 2013 now issued as U.S. Pat. No. 9,190,795 (Docket No.ONAN-001). Each of the aforementioned patent applications, and anyapplications related thereto, is herein incorporated by reference intheir entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable to this application.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to wire termination and morespecifically it relates to a wire termination system for efficientlyconnecting a plurality of wires to an electrical connector.

Description of the Related Art

Any discussion of the related art throughout the specification should inno way be considered as an admission that such related art is widelyknown or forms part of common general knowledge in the field.

There are various types of electrical connectors used today includingbut not limited to fine wire terminations, pinned connectors, terminalblocks, plug and socket connectors, medical connectors, transitiondevices and custom connectors. Conventional electrical connectorsinclude a plurality of connector pins that have a correspondingplurality of wires from a cable that must be soldered together accordingto a pinout which cross-references the wires to the connector pins.Today, technicians manually connect each individual wire to acorresponding connector pin on the electrical connector. The number ofconnector pins on a connector range from 2 to greater than 100 connectorpins which receive a corresponding number of wires.

Medical probes typically have numerous connector pins within anelectrical connector that require a corresponding number of fine wiresto be connected to. For example, modern catheters may contain more than120 40-gauge wires connecting medical transducers. A skilled technicianmanually connects each of the fine wires to a corresponding connectorpin on the electrical connector utilizing a soldering device (e.g.soldering iron or soldering gun). The technician must identify a finewire and a corresponding connector pin where the fine wire will beconnected to. After identifying the proper connection point for the finewire, the technician then must position the fine wire adjacent to theconnector pin and then heats the solder with the soldering device tomelt upon both the fine wire and the connector pin. Once the technicianremoves the soldering device, the melted solder solidifies therebyphysically and electrically connecting the fine wire to the connectorpin. The technician manually repeats this process for each individualfine wire until all of the fine wires are connected.

As can be appreciated, the manual process of soldering a plurality ofwires to an electrical connector is labor intensive, time consuming,costly and creates a significant amount of discarded material. Errors bytechnicians soldering wires to electrical connectors are common witherror rates approaching 25% with some medical connectors where the wiresare very thin and where a single mistake typically results in thecomplete loss of the connector. For example, technicians may mistakenlyconnect a wire to an incorrect connector pin thereby resulting in adefective electrical connector being produced thereby requiringadditional time to fix or the complete loss of the electrical connector.Errors by technicians are further compounded by the increasingly smallerwires used in electrical connectors today, particularly in the medicalindustry, where some devices require 100 or more connector pins within asquare centimeter. To make matters worse for technicians, they mustoften times connect extremely fine wires having a 40-gauge or 50-gaugesize.

Because of the inherent problems with conventional wire terminationsystems, there is a need for a new and improved wire termination systemfor efficiently connecting a plurality of wires to an electricalconnector.

BRIEF SUMMARY OF THE INVENTION

The invention generally relates to a wire termination system whichincludes a heat applicator device that selectively applies heat to aspecific connector pin within an electrical connector so that acorresponding wire may be soldered to the connector pin. The heatapplicator device applies heat to a first connector pin for a period oftime for soldering of a first wire to the first connector pin and thenthe heat is removed. The heat applicator device then applies heat to thenext connector pin for soldering a next wire to the next connector withthe process continuing until all of the wires are soldered to theircorresponding connector pins on the electrical connector.

There has thus been outlined, rather broadly, some of the features ofthe invention in order that the detailed description thereof may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are additional features of theinvention that will be described hereinafter and that will form thesubject matter of the claims appended hereto. In this respect, beforeexplaining at least one embodiment of the invention in detail, it is tobe understood that the invention is not limited in its application tothe details of construction or to the arrangements of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced andcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose of thedescription and should not be regarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Various other objects, features and attendant advantages of the presentinvention will become fully appreciated as the same becomes betterunderstood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views, and wherein:

FIG. 1a is an upper perspective view of the present invention with anelectrical connector positioned within the heat unit.

FIG. 1b is an upper perspective view of the present invention with aportion of the housing removed and the electrical connector removed fromthe heat unit.

FIG. 2 is an upper perspective view of the heat unit with the electricalconnector removed.

FIG. 3a is an exploded upper perspective view of the heat applicatordevice, the electrical connector and the wires of a cable to beconnected to the connector pins within the electrical connector.

FIG. 3b is a top view of an exemplary electrical connector.

FIG. 3c is a bottom view of an exemplary electrical connector.

FIG. 4 is a cross sectional view taken along line 4-4 of FIG. 3 a.

FIG. 5a is an upper perspective view with the electrical connectorpositioned upon the heat unit.

FIG. 5b is an upper perspective view of the electrical connectorpositioned upon the heat unit with a first wire inserted into a firstconnector receptacle.

FIG. 5c is an upper perspective view of the electrical connectorpositioned upon the heat unit with a second wire inserted into a secondconnector receptacle.

FIG. 5d is an upper perspective view of the electrical connectorpositioned upon the heat unit with a third wire inserted into a thirdconnector receptacle.

FIG. 5e is an upper perspective view of the electrical connectorpositioned upon the heat unit with a fourth wire inserted into a fourthconnector receptacle.

FIG. 5f is an upper perspective view of the electrical connectorpositioned upon the heat unit with a fifth wire inserted into a fifthconnector receptacle.

FIG. 5g is an upper perspective view of the electrical connectorpositioned upon the heat unit with a sixth wire inserted into a sixthconnector receptacle.

FIG. 5h is an upper perspective view of the electrical connectorpositioned upon the heat unit with a seventh wire inserted into aseventh connector receptacle.

FIG. 6 is an exploded upper perspective view of a wire with respect to aconnector pin and a heat receptacle.

FIG. 7 is an exploded upper perspective cutaway view of FIG. 6 showingthe solder within the connector receptacle of the connector pin.

FIG. 8a is an upper perspective cutaway view of the connector pinpositioned within the heat receptacle to melt the solder.

FIG. 8b is an upper perspective cutaway view of the wire inserted intothe connector receptacle and the melted solder.

FIG. 8c is an upper perspective cutaway view of the wire connectedwithin the connector pin and the connector pin removed from the heatreceptacle.

FIG. 9 is an upper perspective view of a plurality of heat devices thatapply heat to selected connector pins of the electrical connector from adistance without direct physical contact.

FIG. 10a is a side view of a heat conductor thermally connected betweena tubular thermal connector and a heat receptacle.

FIG. 10b is front view of the heat conductor thermally connected betweenthe tubular thermal connector and the heat receptacle.

FIG. 10c is a cross sectional view taken along line 10 c-10 c of FIG. 10b.

FIG. 11a is a side view of a heat receptacle.

FIG. 11b is a cross sectional view taken along line 11 b-11 b of FIG. 11a.

FIG. 12a is an exploded upper perspective view of a heat receptacle withcontact clips.

FIG. 12b is an end view of a heat receptacle having a plurality ofcontact clips.

FIG. 12c is a cross sectional view taken along line 12 c-12 c of FIG. 12b.

FIG. 13a is an upper perspective view of another variation of the heatreceptacle.

FIG. 13b is an end view of the variation of the heat receptacle shown inFIG. 13 a.

FIG. 13c is an upper perspective view of the variation of the heatreceptacle shown in FIG. 13a with additional cutouts.

FIG. 14 is an upper perspective view of a heat device having atelescoping pin.

FIG. 15 is an upper perspective view of a heat receptacle having a pairof prongs.

FIG. 16 is a side cross sectional view of another variation of the heatreceptacle having contact clips and a hood.

FIG. 17 is a flowchart illustrating the overall functionality of thepresent invention.

FIG. 18 is a block diagram illustrating the control unit incommunication with the display unit and the heat applicator device.

FIG. 19 is an upper perspective view of a second embodiment of thepresent invention with the electrical connector and the wires inexploded view.

FIG. 20 is an upper perspective view of the second embodiment with theelectrical connector seated within the present invention and the wiresinserted into the electrical connector.

FIG. 21 is a side view of the second embodiment illustrating the roboticheater.

FIG. 22 is a side cutaway view of the second embodiment.

FIG. 23 is a side cutaway view of the second embodiment with the heatingelement moved upwardly to physically contact one of the connector pinsof the electrical connector.

FIG. 24 is a top view of the present invention with the wires insertedinto the electrical connector.

FIG. 25a is a top view of the alignment plate showing the retentionmember moved outwardly away from the electrical connector to release orinsert the electrical connector into the receiver opening in thealignment plate.

FIG. 25b is a top view of the alignment plate showing the retentionmember moved inwardly toward the electrical connector to secure theelectrical connector within the receiver opening.

FIG. 26 is a top cutaway view of the second embodiment.

FIG. 27 is a top cutaway view of the second embodiment moving theheating element in a first direction.

FIG. 28 is a top cutaway view of the second embodiment moving theheating element in a second direction.

FIG. 29 is a block diagram of the second embodiment illustrating thecommunications with the control unit and the elements of the secondembodiment.

FIG. 30 is a side view of a third embodiment of the present inventionusing actuators to move the heating element for the robotic heater.

FIG. 31 is a block diagram of the third embodiment illustrating thecommunications with the control unit and the elements of the thirdembodiment.

FIG. 32 is a side view of a fourth embodiment of the present inventionusing a robotic arm to move the heating element for the robotic heater.

DETAILED DESCRIPTION OF THE INVENTION A. Overview of Invention

FIGS. 1 through 18 illustrate the present invention comprised of thewire termination system 10. FIGS. 19 through 29 illustrate a secondembodiment for a robotic wire termination system and FIGS. 30 through 31illustrate a third embodiment for a robotic wire termination system.FIG. 32 illustrates a fourth embodiment for a robotic wire terminationsystem.

The wire termination system 10 generally includes a heat applicatordevice 30 that selectively applies heat to a specific connector pinwithin an electrical connector 20 so that a corresponding wire may besoldered to the connector pin. The heat applicator device 30 appliesheat to a first connector pin for a period of time for soldering of afirst wire to the first connector pin and then the heat is removed. Theheat applicator device 30 then applies heat to the next connector pinfor soldering a next wire to the next connector with the processcontinuing until all of the wires 16 a-g are soldered to theircorresponding connector pins 23 a-g on the electrical connector 20.

B. Electrical Connector

The electrical connector 20 may be comprised of any device whereelectrical wires 16 a-g are terminated at. There are various types ofelectrical connectors 20 used today including but not limited to finewire terminations, pinned connectors, terminal blocks, plug and socketconnectors, medical connectors, transition devices and customconnectors. The electrical connector 20 may be for various types ofindustries such as but not limited to the medical industry.

As illustrated in FIGS. 1b through 4 of the drawings, the electricalconnector 20 includes a plurality of connector pins 23 a-g that extendthrough an insulator housing 22. The connector pins 23 a-g are comprisedof an electrical conductive material such as metal. The insulatorhousing 22 electrically insulates the respective connector pins 23 a-gand also supports the connector pins 23 a-g. The insulator housing 22may have various shapes (e.g. circular as illustrated in FIGS. 3b and 3c), thicknesses and sizes.

The connector pins 23 a-g are typically parallel with one another andmay form various types of shapes and patterns. Also, the number ofconnector pins 23 a-g on a connector 20 may range from 2 connector pins23 a-g to greater than 100 connector pins 23 a-g.

The connector pins 23 a-g have a male connecting end that typically hasa tapered end or pointed end used to electrically connect the electricalconnector 20 to a corresponding electrical socket or the like as bestillustrated in FIGS. 3a and 3c of the drawings. The connecting endtypically is comprised of a solid pin structure as illustrated in FIG. 4of the drawings. The male connecting end of the connector pins 23 a-gextends outwardly from a first side of the insulator housing 22 asillustrated in FIGS. 2, 3 a and 4 of the drawings.

The connector pins 23 a-g each include a corresponding connectorreceptacle 24 a-g that is positioned opposite of the male connecting endof the connector pins 23 a-g. The distal ends of the wires 16 a-g aresoldered to the connector receptacles 24 a-g according to a pinout toform a physical and electrical connection between the same.

FIGS. 3a, 3b and 4 illustrate a preferred embodiment of the connectorreceptacles 24 a-g comprised of a female connecting end having a tubularstructure. The connector receptacles 24 a-g may have a non-tubularstructure as long as the connector receptacles 24 a-g allow for thesoldering of the wires 16 a-g. The connector receptacles 24 a-gpreferably extend outwardly from a second side of the insulator housing22 of the electrical connector 20 which is opposite of the first side.The connector receptacles 24 a-g preferably have an upper opening thatmay be flush with, recessed or extending past the second side of theinsulator housing 22 of the electrical connector 20 as best illustratedin FIG. 4 of the drawings. The connector receptacles 24 a-g may allextend the same distance from the second side of the electricalconnector 20 as illustrated in FIGS. 3a and 5a of the drawings or theconnector receptacles 24 a-g may extend outwardly from the second sideat different distances (e.g. central located receptacles may extendoutwardly further than outer located receptacles).

The connector receptacles 24 a-g are preferably prefilled with a solder12 prior to attaching the electrical connector 20 to the heat applicatordevice 30 or applying heat to any of the connector pins 23 a-g. Forexample, the interior cavity of the connector receptacles 24 a-g may beat least partially filled with solder balls. The prefilling of theconnector receptacles 24 a-g with solder 12 allows for the electricalconnector 20 to be positioned within the heat applicator device 30 andheat to be selectively applied to the connector pins 23 a-g without theoperator having to manually apply solder 12 to secure the wires 16 a-gto the connector receptacles 24 a-g.

Various types of solder 12 may be utilized such as but not limited tolead solder, lead-free solder, solder balls, solder paste and flux-coresolder. The solder 12 may be comprised of various fusible metal alloysthat have a relatively low melting point capable of physically andelectrically connecting the wires 16 a-g to the connector pins 23 a-g ofthe electrical connector 20.

C. Cable and Wires

FIG. 3a illustrates a cable 14 with a plurality of wires 16 a-gextending from the tubular insulation of the cable 14. It can beappreciated that the wires 16 a-g to be connected to the electricalconnector 20 do not have to be part of an insulated cable 14 and insteadmay be separate of one another without a common sheathing. The wires 16a-g may have various lengths and sizes.

The plurality of wires 16 a-g from the cable 14 are soldered to therespective connector pins 23 a-g according to a pinout whichcross-references the wires 16 a-g to the corresponding connector pins 23a-g. The pinout may be a diagram or chart used to reference the specificconnector pins 23 a-g and corresponding wires 16 a-g. The pinout may becolor coded, numbered or otherwise coded to assist a technician inpositioning the wires 16 a-g adjacent to and upon their respectiveconnector pins 23 a-g for proper connection of the wires 16 a-g to theconnector pins 23 a-g. Incorrect connection of any wire to theelectrical connector 20 can result in the complete loss of theelectrical connector 20.

D. Heat Applicator Device

FIGS. 1a through 5h and 9 illustrate an exemplary heat applicator device30 utilized to apply heat to the individual connector pins 23 a-gsufficient to melt the solder 12 (e.g. 190 degrees F. or greater) into aliquid state and thereby resulting in the soldering of the wires 16 a-gto the connector pins 23 a-g. The heat applicator device 30 may be aportable device or a non-movable fixture.

The heat applicator device 30 includes a power switch 31 that a useruses to turn the heat applicator device 30 on/off as illustrated in FIG.1a of the drawings. The heat applicator device 30 further preferablyincludes a control switch 34 that the technician manipulates to controlwhich connector pin 23 a-g is heated and for how long.

As illustrated in FIGS. 1a through 2 of the drawings, the heatapplicator device 30 is comprised of an upper support member 32 (e.g.platform) that supports a heating unit 40 that the electrical connector20 physically and thermally connects to. The heat applicator device 30further is comprised of a lower support member 41 that supports the heatelements 48 a-g. The upper support member 32 and the lower supportmember 41 preferably are comprised of a heat resistant material. Theupper support member 32 is supported above the lower support member 41with a plurality of support members extending between the upper supportmember 32 and the lower support member 41. The heat elements 48 a-g areelectrically connected to the heat applicator device 30 and the controlunit 60 as illustrated in FIGS. 1b , 2 and 18 of the drawings.

The heat elements 48 a-g used in the present invention are comprised ofany device capable of generating heat sufficient to melt solder 12 suchas but not limited to ceramic heating elements. The heat elements 48 a-gmay generate heat via electricity or other heating option. The heatelements 48 a-g pass through the lower support member 41 and upwardly asbest illustrated in FIG. 4 of the drawings.

A corresponding plurality of thermal connectors 50 a-g are in thermalcontact with the heat elements 48 a-g to conduct the heat generated bythe heat elements 48 a-g. The thermal connectors 50 a-g are preferablycomprised of a heat conductive metal such as copper. The thermalconnectors 50 a-g are further preferably comprised of a tubularstructure that snugly surrounds the heat elements 48 a-g to increase thesurface area contact with the heat elements 48 a-g as best illustratedin FIGS. 4 and 10 c of the drawings.

A plurality of heat conductors 46 a-g are physically and thermallyconnected to the thermal connectors 50 a-g as shown in FIGS. 2, 3 a, 4and 5 a of the drawings. The heat conductors 46 a-g are also preferablycomprised of a heat conductive metal such as copper to transfer the heatconducted by the thermal connectors 50 a-g to the heat receptacles 44a-g within the heating unit 40. The heat conductors 46 a-g are furtherpreferably comprised of an elongated bendable structure to allow forforming of the path of the heat conductors 46 a-g to fit with theheating unit 40 of the heat applicator device 30. FIGS. 2, 3 a, 4 and 5a best illustrate how the heat conductors 46 a-g are bent inwardlytoward the lower end of the heating unit 40 to thermally connect tocorresponding heat receptacles 44 a-g within the heating unit 40. Thisallows for larger sized heating elements and thermal connectors 50 a-gto be used while providing the flexibility required to create thedesired pattern of heat receptacles 44 a-g within the heating unit 40 tomatch smaller sized electrical connectors 20.

The heat receptacles 44 a-g are physically and thermally connected tothe heat conductors 46 a-g opposite of the thermal connectors 50 a-g asillustrated in FIG. 4 of the drawings. Each of the heat receptacles 44a-g is preferably connected to only one of the heat conductors 46 a-g.The heat receptacles 44 a-g are preferably comprised of a heatconductive metal such as copper to effectively transfer the heat fromthe heat conductors 46 a-g to the connector pins 23 a-g of theelectrical connector 20 positioned within the heating unit 40. Theplurality of heat receptacles 44 a-g are each preferably concentricallyaligned with a corresponding connector pin of the plurality of connectorpins 23 a-g.

The heat receptacles 44 a-g preferably are comprised of a tubularstructure adapted to receive the connector pins 23 a-g of the electricalconnector 20. The heat receptacles 44 a-g may have various crosssectional shapes such as circular, square, rectangular or oval. The heatreceptacles 44 a-g may be comprised of a non-tubular structure (e.g.flat, concave, etc.). The heating unit 40 further preferably includes aninsulated housing 42 that the heat receptacles 44 a-g are positionedwithin, however, the heat receptacles 44 a-g may also be directlypositioned within the upper support member 32.

The pattern for the heat receptacles 44 a-g matches the pattern of theconnector pins 23 a-g so that the electrical connector 20 may beconnected to the heating unit 40 by the connector pins 23 a-g. As can beappreciated, the heat receptacles 44 a-g within the heating unit 40 maybe comprised of any type of pattern and any number. For example, FIG. 3aillustrates seven heat receptacles 44 a-g within the heating unit 40with a center heat receptacle 44 a surrounded in a circular pattern bythe other receptacles 44 b-g. It is preferable that the heat receptacles44 a-g, the corresponding heat conductors 46 a-g and the correspondingthermal connectors 50 a-g are each comprised of a unitary structurewithout any thermal barriers comprised of the same material such asmetal (e.g. copper) as best illustrated in FIGS. 4 and 10 c of thedrawings.

The heat receptacles 44 a-g may have a tubular structure wherein theinterior passage of the heat receptacles 44 a-g is slightly larger thanthe outer diameter/width of the connector pins 23 a-g to allow forphysical engagement of the connector pins 23 a-g by the interior surfaceof the heat receptacles 44 a-g. In addition, the heat receptacles 44 a-gmay include one or more contact clips 47 that extend inwardly from theinterior wall of the heat receptacles 44 a-g as illustrated in FIGS. 2through 8 c, 12 a, 12 b and 12 c. The distal ends and/or the crosssectional shape of the contact clips 47 may also have an inwardly curvedstructure to increase the surface contact of the contact clips 47 withthe connector pins 23 a-g as best illustrated in FIG. 12b of thedrawings. The contact clips 47 are preferably angled downwardly awayfrom the opening of the heat receptacles 44 a-g as illustrated in FIG. 4of the drawings. When the connector pins 23 a-g are inserted into theheat receptacles 44 a-g, the contact clips 47 flex towards the innerwall of each of the heat receptacles 44 a-g while ensuring a constantthermal connection with each of the connector pins 23 a-g of theelectrical connector 20.

As a related embodiment, the contact clips 47 may be connected to atubular structure that is positioned over the heat conductor 46 with ahood 72 having a concentric opening positioned over the contact clips 47as illustrated in FIG. 16. As another related embodiment, FIG. 15illustrates a pair of prongs 70 extending outwardly from the heatreceptacle instead of using contact clips 47 within the interior of theheat receptacle.

FIGS. 10a through 11b illustrate an alternative heat receptacle 44 inthermal communication with the heat conductor 46, wherein the heatconductor 46 is in thermal communication with the corresponding thermalconnector. The heat receptacle 44 illustrated in FIGS. 10a through 11band 13a through 13c includes one or more cutouts 45 that extendlongitudinally within the tubular structure of the heat receptacle 44thereby allowing the distal portion of the heat receptacle 44 tophysically and thermally engage the outer surface of the connector pinwhile providing sufficient expansion of the heat receptacle 44. Thedistal portion of the heat receptacle 44 may be straight as shown inFIGS. 10a through 11b or tapered inwardly as illustrated in FIGS. 13athrough 13c . The cutouts 45 preferably only extend partially along thelength of the heat receptacle 44 from the distal end thereof, however,the cutouts 45 may extend along the entire length of the heat receptacle44.

FIG. 14 illustrates wherein the heat receptacles 44 a-g are comprised ofheat devices 52 having a pogo-pin structure that utilizes a telescopingpin 49 that is biased upwardly and that physically engages the connectorpin. Each of the heat receptacles 44 a-g is comprised of the structureof the heat device 52 and are positioned beneath the connector pins 23a-g of the electrical connector 20 to ensure direct physical and thermalcontact for each of the connector pins 23 a-g despite any difference inlength for the connector pins 23 a-g.

FIG. 9 illustrates a plurality of heat devices 52 that do not physicallyconnect with the connector pins 23 a-g but direct heat to specificopposing connector pins 23 a-g. For example, the heat devices 52 may becomprised of a laser (e.g. nitrogen laser) that directs laser light to aspecific one of the connector pins 23 a-g to heat the same.

E. Control Unit

The control unit 60 may be comprised of any type of circuit board orcomputer for practicing the various aspects of the present invention.For example, the control unit 60 can be a personal computer (e.g. APPLE®based computer, an IBM based computer, or compatible thereof) or tabletcomputer (e.g. IPAD®). The control unit 60 may also be comprised ofvarious other electronic devices capable of sending and receivingelectronic data including but not limited to smartphones, mobile phones,telephones, personal digital assistants (PDAs), mobile electronicdevices, handheld wireless devices, smart phones and video viewingunits.

The control unit 60 controls the operation of the present invention. Inparticular, the control unit 60 controls which of the heat elements 48a-g is turned on or off. The control unit 60 is in communication with apower switch 31 which turns the present invention on/off as illustratedin FIG. 18. The control unit 60 further is preferably in communicationwith a control switch 34 which allows the user to manually control whichof the heat elements 48 a-g is activated to produce heat.

FIG. 1a illustrates an exemplary control switch 34 comprised of aturn-knob electrical switch having a plurality of positions that eachrepresent the activation of one of the heat elements 48 a-g and an offposition. For example, FIG. 1a illustrates 8 positions for the controlswitch 34: OFF, 1, 2, 3, 4, 5, 6 and 7. Position “Off” deactivateselectrical power to all of the heat elements 48 a-g, position 1activates the first heat element 48 a, position 2 activates the secondheat element 48 b, position 3 activates the third heat element 48 c,position 4 activates the fourth heat element 48 d, position 5 activatesthe fifth heat element 48 e, position 6 activates the sixth heat element48 f and position 7 activates the seventh heat element 48 g. As can beappreciated, the number of positions for the control switch 34corresponds to the number of heat elements 48 a-g to be controlled.

The control switch 34 may also be comprised of a toggle device or a footpedal that simply advances the heating of the heat elements 48 a-g eachtime the control switch 34 is depressed. For example, in the initialstate the control unit 60 is off until the user depresses the controlswitch 34 which then activates the first heat element 48 a. When theuser releases the control switch 34, the first heat element 48 a isdeactivated. When the user depresses the control switch 34 a secondtime, the second heat element 48 b is activated and when the userthereafter releases the control switch 34 the second heat element 48 isdeactivated and so forth until all of the heat elements 48 a-g have beenactivated to heat the corresponding connector pins 23 a-g.

Instead of operating manually via a control switch 34, the control unit60 may operate automatically by automatically controlling which of theheat elements 48 a-g are activated. For example, the control unit 60 mayautomatically activate the first heat element 48 a for a period of time(e.g. 5 seconds) and/or until a specific temperature is reachedsufficient to heat the corresponding heat receptacle sufficiently tomelt the solder 12 within the corresponding connector receptacle andallow the technician to insert the corresponding first wire 16 a intothe first connector receptacle 24 a. After the period of time, thecontrol unit 60 automatically deactivates the first heat element 48 aand then automatically activates the second heat element 48 b for aperiod of time and/or a specific temperature is reached similar to thefirst heat element 48 a and then deactivates the second heat element 48b after a period of time. This process continues for the remaining heatelements 48 a-g until all of the wires 16 a-g are fully inserted andconnected within the electrical connector 20. It is preferable thatvisual and/or audio indicators are provided to the technician indicatingwhen to insert a specific wire 16 a-g into a corresponding connectorreceptacle 24 a-g.

Various sensors may be in communication with the control unit 60 such asbut not limited to temperature sensors that detect the temperature ofthe heat elements 48 a-g, the thermal connectors 50 a-g, the heatconductors 46 a-g, the heat receptacles 44 a-g, the connector pins 23a-g, the connector receptacles 24 a-g, solder 12 within the connectorreceptacles 24 a-g and/or the wires 16 a-g. The control unit 60 may usethe data received by the sensors in controlling the operation of thepresent invention and may display the same on the display unit 62.

The control unit 60 is further preferably in communication with adisplay unit 62 (e.g. display screen or monitor) to display varioustypes of information. For example, the control unit 60 may display thefollowing types of information on the display unit 62: status of theheat applicator device 30 (e.g. On, Off), the position of the controlswitch 34, an indication of which connector pin is being heated, theconnector pin within the electrical connector 20 that has heat appliedthereto, a graphical representation of the connector pin having heatapplied thereto, a graphical representation of a selected wire for thetechnician to insert into a selected heated connector pin, the amount oftime heat has been applied to a connector pin, the temperature of a heatreceptacle, the temperature of a connector pin and the like.

The control unit 60 may be comprised of any conventional computer orsimilar electronic device. A conventional computer preferably includes aprinter, a hard disk drive, a network interface, and a keyboard. Aconventional computer also includes a microprocessor, a memory bus,random access memory (RAM), read only memory (ROM), a peripheral bus,and a keyboard controller. The microprocessor is a general-purposedigital processor that controls the operation of the computer. Themicroprocessor can be a single-chip processor or implemented withmultiple components. Using instructions retrieved from memory, themicroprocessor controls the reception and manipulations of input dataand the output and display of data on output devices. The memory bus isutilized by the microprocessor to access the RAM and the ROM. RAM isused by microprocessor as a general storage area and as scratch-padmemory, and can also be used to store input data and processed data. ROMcan be used to store instructions or program code followed bymicroprocessor as well as other data. A peripheral bus is used to accessthe input, output and storage devices used by the computer. In thedescribed embodiments, these devices include a display screen, a printerdevice, a hard disk drive, and a network interface. A keyboardcontroller is used to receive input from the keyboard and send decodedsymbols for each pressed key to microprocessor over bus. The keyboard isused by a user to input commands and other instructions to the computersystem. Other types of user input devices can also be used inconjunction with the present invention. For example, pointing devicessuch as a computer mouse, a track ball, a stylus, or a tablet tomanipulate a pointer on a screen of the computer system. The displayscreen is an output device that displays images of data provided by themicroprocessor via the peripheral bus or provided by other components inthe computer. The printer device when operating as a printer provides animage on a sheet of paper or a similar surface. The hard disk drive canbe utilized to store various types of data. The microprocessor, togetherwith an operating system, operate to execute computer code and produceand use data. The computer code and data may reside on RAM, ROM, or harddisk drive. The computer code and data can also reside on a removableprogram medium and loaded or installed onto computer system when needed.Removable program mediums include, for example, CD-ROM, PC-CARD, USBdrives, floppy disk and magnetic tape. The network interface circuit isutilized to send and receive data over a network connected to othercomputer systems. An interface card or similar device and appropriatesoftware implemented by microprocessor can be utilized to connect thecomputer system to an existing network and transfer data according tostandard protocols.

F. Operation of 1^(st) Embodiment

FIG. 17 provides an overview of the present invention. As illustrated inFIGS. 1a and 5a of the drawings, the technician first connects theelectrical connector 20 to the heat applicator device 30 by insertingthe connector pins 23 a-g into the heat receptacles 44 a-g of theheating unit 40. Once the electrical connector 20 is properly connectedto the heat applicator device 30, the user then turns on the heatapplicator device 30.

Heat is first applied to the first connector pin 23 a of the pluralityof connector pins 23 a-g by the heat applicator device 30 therebymelting a first solder 12 within a first connector receptacle 24 a ofthe first connector pin 23 a. The technician then inserts a first wire16 a of the plurality of wires 16 a-g into the first connectorreceptacle 24 a and the melted solder 12 as illustrated in FIG. 5b ofthe drawings. The heat is removed from the first connector pin 23 athereby allowing the first solder 12 to harden thereby physicallysecuring and electrically coupling the first wire 16 a within the firstconnector receptacle 24 a. Heat is then applied to the second connectorpin 23 b of the plurality of connector pins 23 a-g by the heatapplicator device 30 thereby melting a second solder 12 within a secondconnector receptacle 24 b of the second connector pin 23 b. Thetechnician then inserts a second wire 16 b of the plurality of wires 16a-g into the second connector receptacle 24 b and the melted solder 12as illustrated in FIG. 5c of the drawings. The heat is removed from thesecond connector pin 23 b thereby allowing the second solder 12 toharden thereby physically securing and electrically coupling the secondwire 16 b within the second connector receptacle 24 b. The above processof heating a connector pin and inserting a corresponding wire isrepeated until all of the wires 16 a-g are soldered to their respectiveconnector receptacles 24 a-g as illustrated in FIGS. 5c through 5h and17 of the drawings. The heat applicator device 30 is not moved relativeto the electrical connector 20 during or between the application of heatto the first connector pin or subsequent connector pins 23 a-g.

To further illustrate the operation of the present invention as shown inFIG. 1a of the drawings, the technician moves the control switch 34 toposition 1 after positioning the electrical connector 20 within theheating unit 40. When the control switch 34 is in position 1, the firstheating element 48 a is activated thereby heating the first thermalconnector 50 a which thereby heats the first heat conductor 46 a whichthereby heats the first heat receptacle 44 a which thereby heats thefirst connector pin 23 a. When the first connector pin 23 a is heated,the heat is conducted through the length of the first connector pin 23 aupwardly to the first connector receptacle 24 a thereby melting thefirst solder 12 within the first connector receptacle 24 a. The firstwire 16 a is inserted into the first connector receptacle 24 a and theliquefied first solder 12 within by the technician.

After the first wire 16 a is properly inserted, the technician thenturns the control switch 34 to position 2 which then deactivates thefirst heat element 48 a thereby allowing the first solder 12 to cool andharden to retain the first wire 16 a within the first connectorreceptacle 24 a. Also, when the control switch 34 is in position 2, thesecond heat element 48 b is activated so the same process may be appliedfor connecting the second wire 16 b within the second connectorreceptacle 24 b. When the control switch 34 is in position 2, the secondheating element 48 b is activated thereby heating the second thermalconnector 50 b which thereby heats the second heat conductor 46 b whichthereby heats the second heat receptacle 44 b which thereby heats thesecond connector pin 23 b. When the second connector pin 23 b is heated,the heat is conducted through the length of the second connector pin 23b upwardly to the second connector receptacle 24 b thereby melting thesecond solder 12 within the second connector receptacle 24 b. The secondwire 16 b is inserted into the second connector receptacle 24 b and theliquefied second solder 12 within by the technician.

This process continues with position 3 for the third wire 16 c, thefourth wire 16 d, the fifth wire 16 e, the sixth wire 16 f and theseventh wire 16 g until all of the wires 16 a-g are properly terminatedwithin the electrical connector 20. After the wires 16 a-g are properlyterminated within the electrical connector 20, the electrical connector20 is removed from the heating unit 40 of the heat applicator device 30and then tested to ensure that the wires 16 a-g are connected accordingto the proper pinout.

It is preferable that heat is applied to the connector pins 23 a-g tothe portion (the male connecting portion) of the connector pins 23 a-gextending outwardly from the first side of the electrical connector 20opposite of the connector receptacles 24 a-g and wherein heat is notapplied directly to the connector receptacles 24 a-g by the heatapplicator device 30 (i.e. the heat is conducted from the maleconnecting portion of the connector pins 23 a-g upwardly through to theconnector receptacles 24 a-g). In addition, it is preferable that thecontrol unit 60 notifies the technician that a specific wire is ready tobe inserted into a corresponding connector receptacle after a period oftime or other condition is sensed (e.g. temperature of the heatingelement or heat receptacle). It is further preferable that notificationof the technician includes visually indicating on the display unit 62where the selected connector pin is located on the electrical connector20 for the wire to be inserted into. It is further preferable that allof the steps of soldering the wires 16 a-g to the electrical connector20 occur without utilizing a soldering hand tool (e.g. a soldering gunor soldering iron).

G. Robotic Wire Termination System

FIGS. 19 through 32 illustrate a robotic heater that moves a heatingdevice 136 selectively to heat one or more connector pins 23 n of theelectrical connector 20. The robotic heater may be comprised of varioustypes of robot manipulators capable of moving the heating device 136with respect to a selected single selected connector pin 23 n within theelectrical connector 20 that is selected to be heated. The control unit60 is programmed to control the robotic heater to apply heat to theselected connector pin 23 n. The robotic heater includes at least onearm that moves the heating device 136 to a desired location near or incontact with the selected connector pin 23 n to be heated.

The robotic heater preferably applies heat directly to the connectorpins 23 n of the electrical connector 20, however, the robotic heatermay apply heat indirectly to the connector pins 23 n. For example, theelectrical connector 20 may be positioned within a heating unit 40having a plurality of heat receptacles 44 that receive the plurality ofconnector pins 23 n wherein the heat receptacles 44 are thermallycoupled to a plurality of heat conductors 46 similar to the heating unit40 illustrated in FIG. 3a . The robotic heater can apply heat to theconnector pins 23 n and the corresponding connector receptacles 24 n tomelt solder 12 within the receptacles 24 by applying the heat to aselected heat conductor 46 extending from the heating unit 40. It ispreferable that the robotic heater apply heat directly to the connectorpins 23 to efficiently heat the connector pins 23.

The robotic wire termination system includes a frame and a connectorsupport 86 attached to the frame. The frame includes a base 80 and anintermediate support 82 attached to the base 80 having a central openingas illustrated in FIGS. 19, 26 through 28 of the drawings. The centralopening is large enough to allow for movement of a portion of therobotic heater including the heating device 136 in both vertical andhorizontal manners. An upper support 84 is attached to the intermediatesupport 82 to removably support the electrical connector 20 duringsoldering of the wires 16 n within the corresponding receptacles 24 n ofthe electrical connector 20.

The connector support 86 is adapted to receive and support an electricalconnector 20 having a plurality of connector pins 23 and a plurality ofconnector receptacles 24. As illustrated in FIG. 19, the connectorsupport 86 includes a receiver opening 88 having a shape and sizecorresponding to the electrical connector 20 thereby removably receivingthe electrical connector 20. A key portion may extend inwardly into thereceiver opening 88 that corresponds to a cutout within the edge of theelectrical connector 20 as illustrated in FIGS. 25a and 25b of thedrawings.

As shown in FIGS. 19, 20, 24 through 25 b, the connector support 86further includes a retention member 140 attached to the connectorsupport 86 adapted to selectively engage the electrical connector 20 toprevent removal of the electrical connector 20 from the receiver opening88 during the heating of the selected connector pins 23 n. The retentionmember 140 selectively engages an outer edge of the electrical connector20 in a frictional manner thereby allowing the electrical connector 20to be released from the receiver opening 88 if an accidental significantforce is applied to the electrical connector 20 by the robotic heaterduring operation thereof. The retention member 140 has an engaging edgehaving a shape corresponding to a portion of the edge of the electricalconnector 20 to be engaged. The retention member 140 is also preferablyspring biased towards the electrical connector 20 by a spring (e.g.compression spring) thereby maintaining a constant force upon theelectrical connector 20 during the entire process to ensure theelectrical connector 20 is not accidentally discharged from the receiveropening 88. The retention member 140 preferably includes a handleportion extending upwardly for a user to manually engage with theirfingers to pull the retention member 140 away from the electricalconnector 20 thereby allowing the electrical connector 20 be removed andalso allowing for the insertion of a new electrical connector 20 to havethe wires 16 n soldered to.

The connector support 86 may be non-movably or movably positioned withinthe upper support 84. The connector support 86 is preferably rotatablypositioned within the upper support 84 to allow for adjustment of theposition of the connector pins 23 with respect to the robotic heater.Angle markings 87 are imprinted upon the surface of the upper support 84and the connector support 86 to indicate the angular movement of theconnector support 86 with respect to the upper support 84. as bestillustrated in FIG. 24 of the drawings.

The robotic heater includes a robot manipulator to manipulate theposition (horizontal position, vertical position and/or attitude) of theheating device 136 to selectively heat individual connector pins 23 n ofthe electrical connector 20. The robot manipulator includes at least onearm that the heating device 136 is attached to. Utilizing a roboticheater has many advantages over the static system illustrated in FIGS. 1through 18 in that various types of electrical connectors 20 may havethe wires 16 n connected without a physical change in the configurationof the robotic heater because the robotic heater may be programmed toapply heat to various types of electrical connectors 20 in variouspatterns, temperatures, timing and manners.

The robot manipulator is preferably comprised of a programmable robotwhich is programmed to selectively apply heat to each of the connectorpins 23 n in a preselected pattern thereby allowing the worker to insertthe corresponding wire 16 n into the currently heated connectorreceptacle 24 n similar to the process discussed above except where therobot manipulator moves the heating device 136 to the individualconnector pin 23 n to be heated.

The robot manipulator may be comprised of various types of robots androbotic arms capable of moving the heating device 136 in a positionrequired to heat a selected individual connector pin 23 n. Examples ofpreferred robots suitable for usage within the present invention includean articulated robot 152 (FIG. 32), a parallel robot (FIGS. 19 through23, 30), a Cartesian coordinate robot (a.k.a. linear robot). One exampleof a preferred parallel robot for the robot manipulator is a delta robotas illustrated in FIGS. 19 through 23, 30.

The at least one arm of the robot manipulator is adapted to move theheating device 136 to be aligned (preferably concentrically aligned)with the selected connector pin 23 n of the electrical connector 20 forselective heating. The robot manipulator is further adapted to move theheating device 136 transversely with respect to a longitudinal axis ofthe selected connector pin (i.e. the heating device 136 moves along aplane that is transverse with respect to the longitudinal axis of theselected connector pin) as illustrated in FIGS. 27 and 28 of thedrawings. The robot manipulator is further adapted to move the heatingdevice 136 inwardly and outwardly with respect to the selected connectorpin as illustrated in FIGS. 22 and 23 of the drawings. For example, whenthe electrical connector 20 is positioned above the robot manipulatorand the heating device 136 as shown in FIGS. 19 through 23, the robotmanipulator is capable of moving the heating device 136 upwardly,downwardly, and/or horizontally (e.g. forwardly, rearwardly, left,right) thereby aligning the heating device 136 with the selectedconnector pin to be heated.

The delta robot preferably includes three control arms 120 (each controlarm 120 may have a two or three arms for added stability duringoperation). The first ends of the three control arms 120 are movablyconnected to the heating device 136 (or a support member 122 thatsupports the heating device 136) via corresponding first universaljoints. The opposing second ends of the three control arms 120 aremovably connected to motorized devices via corresponding seconduniversal joints. The motorized devices may be comprised of any deviceadapted to move the second ends of the control arms 120 independentlyupwardly, downwardly and/or horizontally thereby manipulating theposition of the heating unit correspondingly.

FIGS. 19 through 23 illustrate an exemplary delta robot having motorizeddevices each comprised of a guide member 90 attached to the frame, adrive motor 110 (e.g. stepper motor), a drive belt 116 connected to thedrive motor 110 and an idler pulley 114, and an arm carrier 100 slidablypositioned upon the guide member 90. Each of the motorized devicespreferably includes an end switch 118 which detects when the arm carrier100 is positioned at the bottom of the guide members 90. The end switch118 communicates the detection of the arm carrier to the control unit 60which makes any adjustments required based on the expected location ofthe arm carrier 100. It is preferable to have two guide members 90extending vertically between the base 80 and the intermediate support 82with each of the guide members 90 comprised of rods. The drive belt 116has a first run and a second run between the drive motor 110 and theidler pulley 114. The arm carrier 100 includes a belt connector 102non-movably attached to the first run of the drive belt 116 asillustrated in FIGS. 19 and 20 of the drawings. The drive belt 116preferably includes teeth and the drive pulley 112 on the drive motor110 also includes corresponding teeth to prevent slippage and to ensurethe location of the heating device 136 is known at all times by thecontrol unit 60 for controlling purposes. The control arms 120 aremovably connected to their corresponding arm carrier 100 by universaljoints. The upward or downward movement of each arm carrier 100determines the position of the heating device 136. The control arms 120are preferably adjustable in length to allow for fine tuning of therobot manipulator by having threaded ends as shown in FIGS. 19 through23 of the drawings.

FIG. 30 illustrates the usage of three linear actuators 150 for thedelta robot. Each of the linear actuators 150 is controlled by thecontrol unit 60 as illustrated in FIG. 31 of the drawings. The linearactuators 150 may be electrically powered or hydraulically poweredactuators 150.

The heating device 136 attached to the arm of the robot manipulator asdiscussed previously. The arm of the robot manipulator is adapted tomove the heating device 136 so that the heating device 136 can applyheat to a selected connector pin 23 n of the electrical connector 20 asalso discussed. The heating device 136 may be comprised of any devicecapable of producing heat sufficient to be thermally conducted by theconnector pins 23 n to melt solder 12 in the connector receptacles 24 nof the electrical connector 20.

The heating device 136 may be comprised of a technology that requiresdirect physical contact with the connector pin 23 n being heated totransfer heat from the heating device 136 to the selected connector pin.One example of a heating device 136 that requires direct or indirectphysical contact to transfer heat is comprised of an electrical heatingelement that includes a heat transfer portion 132 adapted to removablyconnect to a single connector pin 23 n to be heated. The electricalheating element is housed within an insulator 130 (e.g. ceramic) withthe heat transfer portion 132 extending outwardly. As discussedpreviously herein, there are many types of physical devices capable ofphysically connecting to the connector pins 23 n to transfer heat fromthe heating device 136 to the connector pins 23 n. For example, theheating device 136 includes a heat transfer portion 132 that at leastpartially surrounds the selected connector pin during heating of theselected connector pin (e.g. a tubular structure). FIGS. 6 through 8 cillustrate examples of suitable heat transfer portions 132 that allowfor removable physical and thermal connections between the heatingdevice 136 and the connector pins 23 n.

The heating device 136 may also be comprised of a heating technologywhere no physical contact between the heating device 136 and theconnector pin 23 n during the heating of the selected connector pin 23 nis required. An example of a suitable heating device 136 that does notrequire direct physical contact with the selected connector pin duringheating is a laser that directs a laser light towards the selectedconnector pin to heat the selected connector pin. With no physicalcontact (direct or indirect) between the heating device 136 and theconnector pins 23 n, the heating device 136 is preferably concentricallyaligned with the corresponding connector pin 23 n to be heated in adistally spaced manner as illustrated in FIG. 9 of the drawings.

A temperature measuring device 134 is thermally connected to the heatingdevice 136 to measure a temperature of the heating device 136 todetermine the amount of heat being produced by the heating device 136thereby allowing the control unit 60 to determine when to deactivate theheating unit 40. The temperature measuring device 134 is incommunication with the control unit 60 to transmit temperature data tothe control unit 60 measured by the temperature measuring device 134.The temperature measuring device 134 may be comprised of any devicecapable of measuring high temperatures such as, but not limited to, athermocouple.

The control unit 60 is programmable and in communication with the robotmanipulator to control the operation of the robot manipulator. Thecontrol unit 60 is further in communication with the temperaturemeasuring device 134 and the heating device 136 to control theapplication of heat by the heating device 136 during operation. Thecontrol unit 60 is programmed to control the position and movement ofthe arm and the heating device 136 of the robot manipulator to ensureefficient heating of the connector pins 23 n. Based on the feedback fromthe temperature measuring device 134, the control unit 60 determines howmuch electrical power to be provided to the heating device 136 toachieve the desired temperature output to the heat transfer portion 132at any particular time.

In operation, the user inserts an electrical connector 20 into thereceiver opening 88 and releases the retention member 140 which retainsthe electrical connector 20 within the receiver opening 88. Theelectrical connector 20 rests upon a lower lip 89 within the receiveropening 88 as best illustrated in FIG. 23 of the drawings. The connectorpins 23 n of the electrical connector 20 are exposed through the bottomof the receiver opening 88 wherein the heating device 136 may selectiveheat individual connector pins 23 n. The control unit 60 is programmedfor the specific type of electrical connector 20 including the firstconnector pin 23 n to heat to the last connector pin 23 n to heat alongwith the specific connector pins 23 n to be heated therebetween and inthe desired order.

Once the electrical connector 20 is properly seated in the receiveropening 88, the control unit 60 activates the robot manipulator tomanipulate the position of the heating device 136 to heat the firstconnector pin 23 n as preprogrammed wherein solder within thecorresponding first connector receptacle 24 n is melted and the userinserts a corresponding first wire 16 n into the first connectorreceptacle 24 n. When the heating device 136 is directly or indirectlyheating the connector pin 23 n, the robot manipulator positions the heattransfer portion 132 of the heating device 136 in physical and thermalcontact with the connector pin 23 n as illustrated in FIG. 23 of thedrawings. The control unit 60 deactivates the heating device 136 andthen removes the heat transfer portion 132 from contacting the firstconnector pin 23 n. The control unit 60 then activates the robotmanipulator to position the heat transfer portion 132 to the secondconnector pin 23 n to be heated and the above process is repeated forthe second connector pin 23 n. The process continues for the third,fourth, fifth and remaining connector pins 23 n until all of the wires16 n are secured within their respective connector receptacles 24. Oncethe wires 16 n are properly attached physically and electrically withinthe electrical connector 20, the user then moves the retention member140 to allow release of the electrical connector 20 from the receiveropening 88. The entire process is then repeated with the next electricalconnector 20.

Any and all headings are for convenience only and have no limitingeffect. Unless otherwise defined, all technical and scientific termsused herein have the same meaning as commonly understood by one ofordinary skill in the art to which this invention belongs. Althoughspecific terms are employed herein, they are used in a generic anddescriptive sense only and not for purposes of limitation. Allpublications, patent applications, patents, and other referencesmentioned herein are incorporated by reference in their entirety to theextent allowed by applicable law and regulations.

The data structures and code described in this detailed description aretypically stored on a computer readable storage medium, which may be anydevice or medium that can store code and/or data for use by a computersystem. This includes, but is not limited to, magnetic and opticalstorage devices such as disk drives, magnetic tape, CDs (compact discs),DVDs (digital video discs), and computer instruction signals embodied ina transmission medium (with or without a carrier wave upon which thesignals are modulated). For example, the transmission medium may includea telecommunications network, such as the Internet.

The invention is described above with reference to block and flowdiagrams of systems, methods, apparatuses, and/or computer programproducts according to example embodiments of the invention. It will beunderstood that one or more blocks of the block diagrams and flowdiagrams, and combinations of blocks in the block diagrams and flowdiagrams, respectively, can be implemented by computer-executableprogram instructions. Likewise, some blocks of the block diagrams andflow diagrams may not necessarily need to be performed in the orderpresented, or may not necessarily need to be performed at all, accordingto some embodiments of the invention. These computer-executable programinstructions may be loaded onto a general-purpose computer, aspecial-purpose computer, a processor, or other programmable dataprocessing apparatus to produce a particular machine, such that theinstructions that execute on the computer, processor, or otherprogrammable data processing apparatus create means for implementing oneor more functions specified in the flow diagram block or blocks. Thesecomputer program instructions may also be stored in a computer-readablememory that can direct a computer or other programmable data processingapparatus to function in a particular manner, such that the instructionsstored in the computer-readable memory produce an article of manufactureincluding instruction means that implement one or more functionsspecified in the flow diagram block or blocks. As an example,embodiments of the invention may provide for a computer program product,comprising a computer usable medium having a computer-readable programcode or program instructions embodied therein, said computer-readableprogram code adapted to be executed to implement one or more functionsspecified in the flow diagram block or blocks. The computer programinstructions may also be loaded onto a computer or other programmabledata processing apparatus to cause a series of operational elements orsteps to be performed on the computer or other programmable apparatus toproduce a computer-implemented process such that the instructions thatexecute on the computer or other programmable apparatus provide elementsor steps for implementing the functions specified in the flow diagramblock or blocks. Accordingly, blocks of the block diagrams and flowdiagrams support combinations of means for performing the specifiedfunctions, combinations of elements or steps for performing thespecified functions, and program instruction means for performing thespecified functions. It will also be understood that each block of theblock diagrams and flow diagrams, and combinations of blocks in theblock diagrams and flow diagrams, can be implemented by special-purpose,hardware-based computer systems that perform the specified functions,elements or steps, or combinations of special-purpose hardware andcomputer instructions.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof, and it istherefore desired that the present embodiment be considered in allrespects as illustrative and not restrictive. Many modifications andother embodiments of the invention will come to mind to one skilled inthe art to which this invention pertains and having the benefit of theteachings presented in the foregoing description and the associateddrawings. Therefore, it is to be understood that the invention is not tobe limited to the specific embodiments disclosed and that modificationsand other embodiments are intended to be included within the scope ofthe appended claims. Although methods and materials similar to orequivalent to those described herein can be used in the practice ortesting of the present invention, suitable methods and materials aredescribed above. Thus, the present invention is not intended to belimited to the embodiments shown, but is to be accorded the widest scopeconsistent with the principles and features disclosed herein.

What is claimed is:
 1. A method, comprising: applying heat by a heatingdevice to a lower portion of a selected connector pin of a plurality ofconnector pins within an electrical connector so as to melt a volume ofsolder within an interior cavity of a selected connector receptacle of aplurality of connector receptacles within the electrical connector;inserting a selected wire from a plurality of wires into the volume ofsolder within the selected connector receptacle of the plurality ofconnector receptacles; and allowing the volume of solder to solidify soas to make an electrical connection between the selected wire of theplurality of wires and the selected connector pin of the plurality ofconnector pins.
 2. The method of claim 1, wherein the heating device iscomprised of an electrical heating element.
 3. The method of claim 1,wherein the heating device includes a heat transfer portion that atleast partially surrounds the selected connector pin during heating ofthe selected connector pin.
 4. The method of claim 1, wherein theheating device physically contacts the selected connector pin totransfer heat from the heating device to the selected connector pin. 5.The method of claim 1, wherein the heating device does not physicallycontact the selected connector pin during heating of the selectedconnector pin.
 6. The method of claim 1, wherein the heating deviceapplies heat indirectly to the selected connector pin.
 7. The method ofclaim 1, wherein the heating device is adjustable between a firstposition in which the heating device is in physical contact with theselected connector pin and a second position in which the heating deviceis not in physical contact with the selected connector pin.
 8. Themethod of claim 1, wherein the heating device is movable vertically andhorizontally.
 9. The method of claim 1, wherein the heating device ispositioned beneath the electrical connector.
 10. The method of claim 1,further comprising the step of measuring a temperature of the heatingdevice by a temperature measuring device.
 11. The method of claim 10,wherein the temperature measuring device is in communication with acontrol unit to transmit temperature data to the control unit measuredby the temperature measuring device.
 12. The method of claim 1, whereinthe heating device is connected to a moveable arm.
 13. The method ofclaim 12, further comprising the step of controlling a position andmovement of the moveable arm by a control unit, wherein the control unitis in communication with the moveable arm.
 14. A method, comprising:applying heat by a heating device to a lower portion of a first selectedconnector pin of a plurality of connector pins within an electricalconnector so as to melt a first volume of solder within a first interiorcavity of a first selected connector receptacle of a plurality ofconnector receptacles within the electrical connector; inserting a firstselected wire from a plurality of wires into the first volume of solderwithin the first selected connector receptacle of the plurality ofconnector receptacles; allowing the first volume of solder to solidifyso as to make an electrical connection between the first selected wireof the plurality of wires and the first selected connector pin of theplurality of connector pins; moving the heating device; applying heat bythe heating device to a lower portion of a second selected connector pinof the plurality of connector pins within the electrical connector so asto melt a second volume of solder within a second interior cavity of asecond selected connector receptacle of a plurality of connectorreceptacles within the electrical connector; inserting a second selectedwire from the plurality of wires into the second volume of solder withinthe second selected connector receptacle of the plurality of connectorreceptacles; and allowing the second volume of solder to solidify so asto make an electrical connection between the second selected wire of theplurality of wires and the second selected connector pin of theplurality of connector pins.
 15. The method of claim 14, wherein theheating device is movable both vertically and horizontally.
 16. Themethod of claim 14, wherein the heating device is connected to amoveable arm.
 17. The method of claim 16, further comprising the step ofcontrolling a position and movement of the moveable arm by a controlunit, wherein the control unit is in communication with the moveablearm.
 18. The method of claim 14, wherein the heating device ispositioned beneath the electrical connector.
 19. The method of claim 14,wherein the heating device is in physical contact with the firstselected connector pin when heating the first selected connector pin,and wherein the heating device is in physical contact with the secondselected connector pin when heating the second selected connector pin.20. The method of claim 14, wherein the heating device is attached to arobot manipulator having at least one arm.